Radially connected cascade grids

ABSTRACT

In various embodiments, a cascade array may comprise an actuator, a first cascade having a first integral flange, and a second cascade having a second integral flange, wherein the first cascade and the second cascade are operatively coupled to one another via the first integral flange and the second integral flange to form a cascade assembly, and the actuator is disposed between the first cascade and the second cascade.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. Non-Provisional patentapplication Ser. No. 14/681,880, entitled “RADIALLY CONNECTED CASCADEGRIDS,” filed on Apr. 8, 2015, which is a continuation-in-part of, andclaims priority to, and the benefit of U.S. Non-Provisional patentapplication Ser. No. 14/047,224, entitled “ACTUATOR SUPPORT SYSTEM ANDAPPARATUS,” filed on Oct. 7, 2013, the disclosures of which are herebyincorporated by reference in their entirety.

FIELD

The present disclosure relates to cascade-type thrust reverser systemsand, more specifically, to the structural engineering of such cascadegrids.

BACKGROUND

Aircraft engines on a commercial airliner typically include a thrustreverser as part of the nacelle system. The thrust reverser system maybe configured to provide reverse thrust to slow the aircraft, forexample during a landing event after touchdown. One type of thrustreverser design includes cascades which help redirect the air from thefan duct in a reverse thrust direction during thrust reverser operation.The structural support for such cascades may have an impact on theexternal profile and/or aerodynamic features of an aircraft, possiblyreducing the overall efficiency of the aircraft in flight.

SUMMARY

In various embodiments, a thrust reverser system may comprise a firstcascade, a second cascade, an actuator, and a structural connectingmember. The actuator may be radially disposed between the first cascadeand the second cascade. The structural connecting member may be adjacentthe actuator. The structural connecting member may be configured tostructurally join the first cascade and the second cascade.

In various embodiments, a cascade array may comprise an actuator, afirst cascade and a second cascade. The first cascade may have a firstintegral flange. The second cascade may have a second integral flange.The first cascade and the second cascade may be operatively coupled toone another via the first integral flange and the second integral flangeto form a cascade assembly. The actuator may be disposed between thefirst cascade and the second cascade.

In various embodiments, a thrust reverser system may comprise a firstcascade, a second cascade and a first actuator. The first cascade mayinclude a first flange. The second cascade may include a second flange.The first actuator may comprise a body. The body may include a thirdflange and a fourth flange. The first cascade may be operatively coupledto the first actuator by the first flange and the third flange. Thesecond cascade may be operatively coupled to the first actuator by thesecond flange and the fourth flange.

In various embodiments, a propulsion system may comprise a translatingsleeve, a plurality of cascades, a plurality of actuators, a first trackbeam and a second track beam. Each cascade of the plurality of cascadesmay comprise a first flange and a second flange. Each of the actuatorsof the plurality of actuators may comprise a third flange and a forthflange. The first track beam may comprise a fifth flange. The secondtrack beam may comprise a sixth flange. A first cascade of the pluralityof cascade may be coupled to a first actuator of the plurality ofactuators via the first flange and the third flange. The first cascademay be coupled to the first track beam via the second flange and thefifth flange.

In various embodiments, a cascade assembly may comprise a first cascade,a second cascade and a first actuator. The first cascade may include afirst flange and a second flange. The second cascade may include a thirdflange and a fourth flange. The first actuator may comprise a body,which may include a fifth flange and a sixth flange. The first cascademay be coupled to the second cascade through the body of the firstactuator via the first flange being coupled to the firth flange and thethird flange being coupled to the sixth flange.

BRIEF DESCRIPTION OF THE DRAWINGS

The subject matter of the present disclosure is particularly pointed outand distinctly claimed in the concluding portion of the specification. Amore complete understanding of the present disclosure, however, may bestbe obtained by referring to the detailed description and claims whenconsidered in connection with the drawing figures, wherein like numeralsdenote like elements.

FIG. 1 illustrates a perspective view of an aircraft, in accordance withvarious embodiments.

FIG. 2A illustrates a perspective view of a portion of a thrust reversersystem, in accordance with various embodiments.

FIG. 2B illustrates a perspective view of cascade support structure, inaccordance with various embodiments.

FIG. 3A illustrates a perspective view of a portion of a thrust reversersystem, in accordance with various embodiments.

FIG. 3B illustrates a perspective view of cascade support structure, inaccordance with various embodiments.

FIG. 4A illustrates a perspective cross-sectional view of a firstcascade support, in accordance with various embodiments.

FIG. 4B illustrates a perspective cross-sectional view of a secondcascade support, in accordance with various embodiments.

FIG. 5 illustrates a perspective cross-sectional view of a splice platecascade support, in accordance with various embodiments.

DETAILED DESCRIPTION

The detailed description of exemplary embodiments herein makes referenceto the accompanying drawings, which show exemplary embodiments by way ofillustration. While these exemplary embodiments are described insufficient detail to enable those skilled in the art to practice theinventions, it should be understood that other embodiments may berealized and that logical changes and adaptations in design andconstruction may be made in accordance with this invention and theteachings herein. Thus, the detailed description herein is presented forpurposes of illustration only and not of limitation. The scope of theinvention is defined by the appended claims. For example, the stepsrecited in any of the method or process descriptions may be executed inany order and are not necessarily limited to the order presented.Furthermore, any reference to singular includes plural embodiments, andany reference to more than one component or step may include a singularembodiment or step. Also, any reference to attached, fixed, connected orthe like may include permanent, removable, temporary, partial, fulland/or any other possible attachment option. Additionally, any referenceto without contact (or similar phrases) may also include reduced contactor minimal contact.

Furthermore, any reference to singular includes plural embodiments, andany reference to more than one component or step may include a singularembodiment or step. Surface shading lines may be used throughout thefigures to denote different parts, but not necessarily to denote thesame or different materials.

As used herein, “aft” refers to the direction associated with the tail(e.g., the back end) of an aircraft, or generally, to the direction ofexhaust of the gas turbine engine. As used herein, “forward” refers tothe direction associated with the nose (e.g., the front end) of anaircraft, or generally, to the direction of flight or motion.

In various embodiments, a cascade array of a thrust reverser maycomprise a number of individual cascades, also sometimes called cascadegrids or cascade boxes such as, for example, eight cascades per side fora total of 16 cascades per thrust reverser. The thrust reverser systemmay also comprise two or three actuators per side, for a total of fouror six per thrust reverser. These actuators may be located between twoof the cascade boxes.

In various embodiments, each cascade may comprise integral flanges attheir forward and aft ends that are used to structurally attach thecascade to the thrust reverser structure. The forward flanges of thecascades may be attached to forward thrust reverser fixed structure suchas, for example, a torque box. The aft flanges of the cascade may beattached to a frame, such as, for example, an aft cascade ring. Duringreverse thrust operation, air rushes through the cascades in greatvolumes and at great speeds. The aerodynamic features of the cascadeshelp turn this airflow in the desired direction for reverse thrust. Thework that the cascades do on the airflow to turn it results in loadsbeing generated in the cascades, which must be transferred back into thethrust reverser structure and ultimately to the aircraft. The torque boxmay be configured to take or support the fore-aft, radial, and hooploads from the cascades. The aft cascade ring may be designed and/orconfigured to take or support hoop and radial loads. However, the aftcascade ring and the thrust reverser system as a whole may be designedto limit or minimize any fore-aft loads that are applied to the aftcascade ring. The loads are typically all taken by the torque box. Theloads on the aft cascade ring generally impact its overall size andshape and positioning. Because of the limited space available in thearea where the aft cascade ring is positioned in the thrust reverser(typically between the inner and outer panel of the translating sleevewhen the thrust reverser is stowed), it can be difficult to fit an aftcascade ring that is the right size and shape to take the requiredloads. The space claim for the aft cascade ring structure sometimesdrives the need to expand the outer shape of the thrust reverserradially outward to accommodate it.

If adjacent cascade boxes can be radially attached to one another, ahoop load path is established that can allow the aft cascade ring to beadvantageously reduced in size. But, in some cases part of the thrustreverser actuator assembly is positioned between adjacent cascade boxesmaking it difficult to structurally attach them together in the radialdirection.

With reference to FIG. 1, an aircraft 10 may comprise a fuselage 12 anda pair of wings 14. Aircraft 10 may further comprise a propulsion system15 (e.g., a gas turbine engine-nacelle assembly). Propulsion system 15may be mounted to the undersides of wings 14. Propulsion system 15 maycomprise a fan and an engine core. Moreover, the engine core isconfigured to drive a fan to create forward thrust and/or propulsion foraircraft 10. The engine core and fan are typically enclosed and/orhoused in a nacelle. The nacelle may comprise a thrust reverser system.

In various embodiments, and with reference to FIGS. 2A and 2B, thrustreverser system 20 may be a cascade-style thrust reverser system. Thrustreverser system 20 may comprise a translating sleeve 16, one or moreactuators 22 (shown as 22-1, 22-2 and 22-3 in FIG. 2A), and one or morecascades 24 (shown as 24-1, 24-2 and 24-3 in FIG. 2A). Actuators 22 maycomprise a first end and a second end. The first end may be coupled to atorque box 30. The second end may be coupled to translating sleeve 16.In this regard, the first end of actuator 22 is fixed to torque box 30and the second end of actuator 22 is configured to translate forward andaft with translating sleeve 16. In operation, actuators 22 may beextended to translate translating sleeve 16 aft to deploy and activatethrust reverser system 20. Likewise, actuators 22 may retracted totranslate translating sleeve 16 forward to return the thrust reversersystem 20 to a stowed an inactive condition.

In various embodiments, and with momentary reference to FIG. 3B, thesecascades may be housed between inner and outer panels of translatingsleeve 16. Translating sleeve 16 may comprise an outer panel 17 and aninner panel 18. Outer panel 17 and inner panel 18 may be join togetherand may define a channel. When translating sleeve 16 is in a stowed(e.g., a forward position), cascades 24 may be housed within translatingsleeve 16 in the channel defined by outer panel 17 and inner panel 18.

With reference to FIGS. 2A-2B, one example is shown of how tostructurally connect adjacent cascade boxes 24 in a radial directionwhile taking into account the presence of an actuator 22. A structuralconnecting member is positioned or created between the adjacent cascadeboxes which to transfer at least hoop loads and racking loads betweenthem, while also allowing space for the actuator to remain in thisspace. In one example, actuator 22 may comprise a body or outer shell orhousing 23, which may in turn comprise one or more actuator flanges(e.g., actuator flanges 23A and 23B). Actuator flanges 23A and 23B maybe an assembly that attaches to outer shell 23 or may be integrallyformed as a portion of outer shell 23. Cascades 24 may also comprise oneof more cascade flanges (e.g., cascade flanges 24A and 24B). Cascadeflanges 24A and 24B may be an assembly that attaches to cascade 24 ormay be integrally formed as a portion of cascade 24. Actuator flanges23A and 23B may be configured to couple to and support cascade flanges24A and 24B. In this regard, one or more cascades 24 may be joinedand/or supported by one or more actuators 22 at actuator flanges 23A and23B and cascade flanges 24A and 24B. The connection between the flanges(e.g., actuator flanges 23A and 23B and cascade flanges 24A and 24B) maybe secured by any suitable fastener, bond, connector, and/or the like.Structurally, loads on cascade box 24-1 may be transferred to cascadeflange 24A, and in turn to actuator flange 23A and outer shell 23, andthen to actuator flange 23B, and in turn to cascade flange 24B andcascade box 24-2. These actuator and cascade flanges may run the entirelength of the actuators and cascades, or they may be discreet flanges,for example a flange at the forward end and a flange at the aft end maybe provided which several discreet flanges in between, according to theparticular application and the need.

With reference to FIGS. 3A and 3B, one method is illustrated ofestablishing a radial connection between the top or bottom cascade box24 on a thrust reverser half and the adjacent track beam (also sometimescalled a hinge or latch beam). Thrust reverser system 20 may include oneor more track beams 28 (e.g., track beams 28-1 and 28-2 as shown in FIG.3A) extending forward to aft. Actuator 22 may also be configured tomount to track beam 28 and cascade 24. Body 23 may comprise one or moreactuator flanges (e.g., actuator flanges 23C and 23D). Track beam 28 maycomprise one or more track beam flanges (e.g., track beam flange 28A).Cascade 24 may comprise one or more cascade flanges (e.g., cascadeflange 24C). Track beam flange 28A may be configured to couple to and/orbe joined to actuator flange 23D. Cascade flange 24C may be configuredto couple to and/or be joined to actuator flange 23C. In this regard,outer shell 23 may support and/or couple cascade 24 to track beam 28. Asdiscussed herein, the connection between the flanges (e.g., track beamflanges 28A and actuator flange 23D) may be secured by any suitablefastener, bond, connector, and/or the like. Similar to the previousdescription, this structural attachment of a cascade box to the trackbeam allows for the transfer of at least racking and hoop loads throughthe flanges and the outer shells of the actuators. When used incombination, the two methods in FIGS. 2B and 3B create an array ofcascade boxes 24 that are capable of transferring their hoop loadsthrough one another to either of the track beams 28-1 or 28-2. Becausethe cascade boxes have more internal load carrying capability, the sizeof the aft cascade ring may be reduced due to its reduced requirementfor support.

With reference to FIGS. 4A-4B, other examples of structural connectingmembers and methods between adjacent cascade boxes 24 are illustrated.As shown in FIG. 4A, actuator 22 may be surrounded by a two piece clamp.The two piece clamp may comprise a first clamp half 42-1 and a secondclamp half 42-2. First clamp half 42-1 may comprise a first flange 44-1and a second flange 44-2. Similarly, second clamp half 42-2 may comprisea third flange 44-3 and a fourth flange 44-4. These flanges (e.g., firstflange 44-1, second flange 44-2, third flange 44-3, and/or fourth flange44-4) may be configured to operatively couple to and/or engage cascade24-1 and/or cascade 24-2.

First clamp half 42-1 and second clamp half 42-2 may surround actuator22 but may not clamp to actuator 22 or even contact (in normaloperation) outer shell 23. In this regard, the two piece clamp does notengage and/or load actuator 22. Rather, actuator 22 is separated fromfirst clamp half 42-1 and second clamp half 42-2 by a gap 46. Gap 46 maybe any suitable size to minimize and/or eliminate contact betweenactuator 22 and the two piece clamp. In this arrangement, actuator 22may float when the thrust reverser is deployed. This arrangement allowsactuator 22 to take fore-aft load only when the thrust reverser isdeployed and avoid potentially damaging or life-limiting side loads.This arrangement also defines a load path between first cascade 24-1 andsecond cascade 24-2 and through first clamp half 42-1 (i.e., throughfirst flange 44-1, and/or second flange 44-2) and second clamp half 42-2(i.e. through third flange 44-3, and/or fourth flange 44-4) to bearand/or distribute the hoop loads and radial loads across the cascadearray. In this regard, the hoop loads and radial loads are isolated fromthe actuator, while allowing the actuator to remain in its positioncircumferentially spaced from and between each of the cascade boxes 24-1and 24-2.

In various embodiments and with particular reference to FIG. 4B,actuator 22 may be clamped by first clamp half 42-1 and second clamphalf 42-2. In this arrangement, actuator 22 may bear and translateradial, hoop and fore-aft loads through first clamp half 42-1 (i.e.,through first flange 44-1, and/or second flange 44-2) and second clamphalf 42-2 (i.e. through third flange 44-3, and/or fourth flange 44-4).This arrangement may cause the size and/or materials used to makeactuator 22 and/or the body of actuator 22 to be designed to bear theloads applied to actuator 22.

In various embodiments and with reference to FIG. 5, first cascade 24-1and second cascade 24-2 may comprise a first integral flange 54-1 and asecond integral flange 54-2, respectively. First integral flange 54-1and second integral flange 54-2 may be coupled to one another with asplice plate 52. First integral flange 54-1 and second integral flange54-2 may be configured to pass by and at least partially surroundactuator 22. In this regard, first integral flange 54-1 and secondintegral flange 54-2 may create a load path between first cascade 24-1and second cascade 24-2, which may isolate actuator 22 from the hoop andradial loads that pass through the cascades, while allowing the actuatorto remain in its position circumferentially spaced from and between eachof the cascade boxes 24-1 and 24-2.

In various embodiments, typical cascade-style thrust reverser systemscomprise an aft cascade ring. This aft cascade ring generally couples aplurality of cascades to one another over the radius of the cascadeassembly at the aft end of the cascade assembly. The aft cascade ringmay be configured to support the hoop defined by the cascade assembly.In various embodiments, this aft cascade ring may impose designlimitations on the outer and/or overall envelope of the nacelle surfaceincluding, for example, the translating sleeve. In various embodiments,creating a load and support path with between actuators 22, cascades 24,and track beams 28 may allow the aft cascade ring to be minimized and/orremoved from the thrust reverser system 20. Moreover, in variousembodiments, actuator 22 may be capable of operating with a side loadapplied.

Benefits, other advantages, and solutions to problems have beendescribed herein with regard to specific embodiments. Furthermore, theconnecting lines shown in the various figures contained herein areintended to represent exemplary functional relationships and/or physicalcouplings between the various elements. It should be noted that manyalternative or additional functional relationships or physicalconnections may be present in a practical system. However, the benefits,advantages, solutions to problems, and any elements that may cause anybenefit, advantage, or solution to occur or become more pronounced arenot to be construed as critical, required, or essential features orelements of the inventions. The scope of the inventions is accordinglyto be limited by nothing other than the appended claims, in whichreference to an element in the singular is not intended to mean “one andonly one” unless explicitly so stated, but rather “one or more.”Moreover, where a phrase similar to “at least one of A, B, or C” is usedin the claims, it is intended that the phrase be interpreted to meanthat A alone may be present in an embodiment, B alone may be present inan embodiment, C alone may be present in an embodiment, or that anycombination of the elements A, B and C may be present in a singleembodiment; for example, A and B, A and C, B and C, or A and B and C.

Systems, methods and apparatus are provided herein. In the detaileddescription herein, references to “various embodiments”, “oneembodiment”, “an embodiment”, “an example embodiment”, etc., indicatethat the embodiment described may include a particular feature,structure, or characteristic, but every embodiment may not necessarilyinclude the particular feature, structure, or characteristic. Moreover,such phrases are not necessarily referring to the same embodiment.Further, when a particular feature, structure, or characteristic isdescribed in connection with an embodiment, it is submitted that it iswithin the knowledge of one skilled in the art to affect such feature,structure, or characteristic in connection with other embodimentswhether or not explicitly described. After reading the description, itwill be apparent to one skilled in the relevant art(s) how to implementthe disclosure in alternative embodiments.

Furthermore, no element, component, or method step in the presentdisclosure is intended to be dedicated to the public regardless ofwhether the element, component, or method step is explicitly recited inthe claims. No claim element herein is to be construed under theprovisions of 35 U.S.C. 112(f) unless the element is expressly recitedusing the phrase “means for.” As used herein, the terms “comprises”,“comprising”, or any other variation thereof, are intended to cover anon-exclusive inclusion, such that a process, method, article, orapparatus that comprises a list of elements does not include only thoseelements but may include other elements not expressly listed or inherentto such process, method, article, or apparatus.

I claim:
 1. A cascade array, comprising: an actuator; a first cascadehaving a first integral flange; and a second cascade having a secondintegral flange, wherein the first cascade and the second cascade areoperatively coupled to one another via the first integral flange and thesecond integral flange to form a cascade assembly, the actuator isdisposed between the first cascade and the second cascade, and the firstintegral flange and the second integral flange extend towards oneanother and extend past at least a portion of the actuator.
 2. Thecascade array of claim 1, wherein the cascade assembly is configured toat least partially surround the actuator.
 3. The cascade array of claim1, wherein the cascade assembly is configured to isolate the actuatorfrom radial loads and hoop loads.
 4. The cascade array of claim 1,further comprising a splice plate.
 5. The cascade array of claim 4,wherein the splice plate is configured to operatively couple the firstcascade and the second cascade together to form the cascade assembly. 6.The cascade array of claim 1, wherein the cascade assembly is housedwith a translating sleeve when a thrust reverser system is in the stowedposition.
 7. The cascade array of claim 1, wherein the cascade assemblyis operatively coupled to a torque box.
 8. The cascade array of claim 5,wherein the splice plate is disposed radially outward from the firstintegral flange and the second integral flange.
 9. The cascade array ofclaim 8, wherein a radially inner surface of the splice plate is coupledto a radially outer surface of the first integral flange and a radiallyouter surface of the second integral flange.